Tobacco articles and methods

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No. 13/078,227 filed on Apr. 1, 2011, which is a continuation of U.S. application Ser. No. 11/626,211 filed on Jan. 23, 2007, which claims priority to U.S. provisional application Ser. No. 60/764,108 filed on Jan. 31, 2006, the contents of these previous applications are incorporated herein by reference.

TECHNICAL FIELD

This document relates to tobacco articles and methods of making such tobacco articles.

BACKGROUND

Smokeless tobacco products are manufactured in a variety of forms including chewing tobacco, dry snuff, and moist snuff. Generally, these types of products are made using one or more of the following steps: cutting or grinding the tobacco into a particular size; dipping or spraying the tobacco with a casing solution; partially drying the tobacco; storing the tobacco in containers for a period of time; and packaging it.

An adult consumer who chooses to use a smokeless tobacco product selects the product according to their individual preferences, such as flavor, cut of tobacco, form, ease of use, and packaging.

SUMMARY

Some embodiments of a tobacco article may include tobacco disposed in a porous matrix. The tobacco article may provide tobacco, tobacco constituents, or both tobacco and tobacco constituents to the adult consumer's mouth in the form of particles, liquid, or vapor so as to provide tobacco satisfaction to the adult consumer. For example, the tobacco article may comprise a substantially cylindrical body having tobacco disposed in the pores of a porous matrix so that the adult consumer may draw air and tobacco vapors through the pores and into the consumer's mouth for receiving tobacco and tobacco constituents. In another example, the tobacco article may comprise a conduit body having tobacco disposed in the pores of a porous matrix, and at least a portion of the conduit body may be configured to be wetted (e.g., temporarily exposed to water or another liquid) so that the consumer may draw liquid from the wetted portion, through the porous matrix, and to the consumer for the tobacco or tobacco constituents. In a further example, the tobacco article may comprise a body configured to be wholly received by the consumer, and at least a portion of the body may have tobacco disposed in the pores of a porous matrix so that the consumer's saliva or another liquid may pass through the pores for releasing tobacco or tobacco constituents into the consumer's mouth. In a further aspect of this particular embodiment, another portion of the article may also be comprised of said pores of the porous matrix so that the consumer's saliva may be absorbed in a manner to alleviate the need for expectoration. In particular embodiments of a tobacco article, the tobacco may be integrally molded with a plastic material, said material being hydrophobic, hydrophilic or a combination thereof so that at least a portion of the tobacco is disposed in pores of the matrix.

In some embodiments, a tobacco article may comprise a substantially cylindrical body including a porous matrix and an outer shell surface impermeable to migration of tobacco constituents. The outer shell surface may at least partially surround the porous matrix. The article may also comprise tobacco disposed in pores of the porous matrix so that, when air is passed through the porous matrix, at least one of tobacco or a tobacco constituent is introduced into the air flowing through the article by way of vaporization.

In certain embodiments, a tobacco article may comprise a body including a porous means for retaining tobacco in a network of pores and a shell means for hindering migration of tobacco constituents out from the porous means. The shell means may at least partially surround the porous means. The tobacco article may also comprise tobacco disposed in the pores of the porous means so that, when air is passed through the network of pores, at least one of noncombusted tobacco or a noncombusted tobacco constituent are introduced into the air.

Some embodiments may include a method of introducing noncombusted tobacco or a noncombusted tobacco constituent into air. The method may comprise exposing to the atmosphere first and second end portions of a tobacco article. The tobacco article may include a substantially cylindrical body including a porous matrix and an outer shell surface impermeable to migration of tobacco constituents. The outer shell surface may at least partially surround the porous matrix, and tobacco may be disposed in pores of the porous matrix. The method may also comprise introducing at least one of noncombusted tobacco or noncombusted tobacco constituents into air by forcing the air through the pores of the porous matrix and over the tobacco disposed in the pores.

In other embodiments, a tobacco article may comprise a conduit body including a porous matrix and an outer shell surface. The outer shell surface may at least partially surround the porous matrix. The article may further include tobacco disposed in pores of the porous matrix so that, when at least a portion of the porous matrix is exposed to a liquid, at least one of tobacco or a tobacco constituent is introduced into the liquid. Wetting of said article may occur through complete submersion thereof, through capillary action, or through injection.

In further embodiments, a tobacco article may comprise a body that is wholly receivable in a mouth of a consumer, and the body may include a porous polymer matrix. The article may also comprise tobacco disposed in pores of the porous polymer matrix so that, when the body is exposed to saliva, at least one of tobacco or a tobacco constituent is introduced into the saliva. In further aspect of this particular embodiment, another portion of the article may include a second porous matrix so that the consumer's saliva may be absorbed in a manner to alleviate the need for expectoration.

Some of these embodiments may provide one or more of the following advantages. First, the tobacco article may provide tobacco satisfaction in the form of the experience associated with tobacco organoleptic components and added flavor components that are released in the mouth. Such organoleptic components may relate or contribute to the integrated sensory perception by the adult consumer that includes, for example, any combination of aroma, fragrance, flavor, taste, odor, mouth feel, or the like. Second, the tobacco article may provide tobacco constituents (e.g., flavors, aromas, alkaloids, or the like) to the consumer without combusting any part of the tobacco article. Third, one or more flavor agents may be added to the tobacco article to further enhance the consumer's experience. Fourth, some embodiments of the tobacco article may be manufactured in a repeatable and efficient manner. For example, in some circumstances, the tobacco may be integrally molded with the plastic granules so as to form an impermeable outer shell of polymer material that at least partially surrounds a porous interior matrix that retains the tobacco. Fifth, the tobacco article may be formed of a shape and appearance that resembles traditionally recognized shapes, such as a cigarette, a cigar, or a pouch of chewing tobacco.

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

<figref idref="DRAWINGS">FIG. 1</figref> is a cross-sectional view of a tobacco article in accordance with some embodiments.

<figref idref="DRAWINGS">FIG. 2</figref> is a cross-sectional view of the tobacco article of <figref idref="DRAWINGS">FIG. 1</figref>.

<figref idref="DRAWINGS">FIG. 3</figref> is a cross-sectional view of a tobacco article in accordance with some embodiments.

<figref idref="DRAWINGS">FIGS. 4A-B</figref> are cross-sectional views of a process for manufacturing a tobacco article in accordance with some embodiments.

<figref idref="DRAWINGS">FIGS. 5A-B</figref> are side views of a process for preparing tobacco for use in a tobacco article.

<figref idref="DRAWINGS">FIG. 6</figref> is a magnified view of polymer granules mixed with the tobacco of <figref idref="DRAWINGS">FIG. 5B</figref>.

<figref idref="DRAWINGS">FIG. 7</figref> is a cross-sectional view of a tobacco article in accordance with some embodiments.

<figref idref="DRAWINGS">FIG. 8</figref> is a cross-sectional view of a tobacco article in accordance with some embodiments.

<figref idref="DRAWINGS">FIG. 9</figref> is a cross-sectional view of a tobacco article in accordance with some embodiments.

<figref idref="DRAWINGS">FIG. 10</figref> is a cross-sectional view of the tobacco article of <figref idref="DRAWINGS">FIG. 9</figref>.

<figref idref="DRAWINGS">FIG. 11</figref> is a cross-sectional view of the tobacco article of <figref idref="DRAWINGS">FIG. 10</figref> in accordance with some embodiments.

<figref idref="DRAWINGS">FIG. 12</figref> is a cross-sectional view of a tobacco article in accordance with some embodiments.

<figref idref="DRAWINGS">FIG. 13</figref> is a perspective view of the tobacco article of <figref idref="DRAWINGS">FIG. 12</figref> received in a consumer's mouth.

<figref idref="DRAWINGS">FIG. 14</figref> is a cross-sectional view of the tobacco article of <figref idref="DRAWINGS">FIG. 13</figref> in accordance with some embodiments.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring to <figref idref="DRAWINGS">FIG. 1</figref>, a tobacco article <b>100</b> may include an outer shell surface <b>110</b> that at least partially surrounds a porous matrix <b>120</b>. Tobacco <b>130</b> may be disposed in pores <b>122</b> of the porous matrix <b>120</b> so that the tobacco article <b>100</b> may provide tobacco, tobacco constituents, or both tobacco and tobacco constituents to a consumer's mouth in the form of particles, liquid, or vapor. As described in more detail below, providing of tobacco or tobacco constituents may provide tobacco satisfaction to the consumer.

The tobacco article <b>100</b> may be a noncombustible product in so far as the article <b>100</b> preferably does not require ignition during usage. In these embodiments, the tobacco article <b>100</b> may provide tobacco, tobacco constituents (e.g., flavors, aromas, alkaloids, or the like), or both tobacco and tobacco constituents to the consumer without combusting any part of the tobacco article <b>100</b> (and without igniting the tobacco <b>130</b> inside the article <b>100</b>). Instead, the noncombusted tobacco and/or noncombusted tobacco constituents may be provided to the consumer to provide tobacco satisfaction in the form of the experience associated with tobacco constituents, organoleptic components and added flavor components that are released upon usage. Such organoleptic components may relate or contribute to the integrated sensory perception by the consumer that includes, for example, any combination of aroma, fragrance, flavor, taste, odor, mouth feel, or the like.

The tobacco article <b>100</b> may have a substantially cylindrical outer shape and may be configured to rest between the fingers of a consumer. At least a portion of the tobacco article <b>100</b> may comprise a moldable polymer to permit that portion to be molded into the desired shape. In some embodiments, the outer shell surface <b>110</b> and the porous matrix <b>120</b> may be integrally formed. Also, in some embodiments, the tobacco <b>130</b> and the porous matrix <b>120</b> may be integrally molded so that the tobacco <b>130</b> is disposed in the pores <b>122</b> when the porous matrix is formed. In addition or in the alternative, the tobacco article <b>100</b> may have the tobacco <b>130</b> added through addition of a tobacco slurry containing constituents, organoleptic components and added flavor components added therein after forming by way of injection, absorption or any other like method. The outer shell surface <b>110</b> and the porous matrix <b>120</b> may include the same moldable plastic material or different moldable plastic materials provided that the outer shell surface <b>110</b> is impermeable to the tobacco <b>130</b>.

Still referring to <figref idref="DRAWINGS">FIG. 1</figref>, the outer shell surface <b>110</b> may fully or partially surround the porous matrix <b>120</b> and the tobacco <b>130</b> disposed therein. In this embodiment, the outer shell surface <b>110</b> is formed to fully surround the porous matrix <b>120</b> within a longitudinally extending surface <b>112</b> and first and second cap surfaces <b>114</b> and <b>116</b>. The outer shell surface <b>110</b> may comprise a generally continuous layer of material that is impermeable to the migration of tobacco constituents inside the article <b>100</b>. Alternatively, the article <b>100</b> may be constructed in such a way that the first and second cap surfaces <b>114</b> and <b>116</b> are not created during formation. Either configuration may inhibit the tobacco <b>130</b> or tobacco constituents (e.g., flavors, aromas, alkaloids, or the like) from migrating away from the porous matrix <b>120</b> before the ordinary use of the article <b>100</b> has commenced. In some embodiments, the outer shell surface <b>110</b> may comprise a polymer material that can be formed to provide the substantially continuous layer. Formation of the article <b>100</b> or any parts thereof excluding the tobacco particles <b>130</b>, may be made using any material suitable therefore or combination thereof. For example, the article <b>100</b> may comprise a copolymer of acrylonitrile and methyl acrylate (or an equivalent resin) known to provide barrier characteristics that inhibit the migration of the tobacco constituents, including volatile tobacco constituents. Such a copolymer of acrylonitrile and methyl acrylate is available under the trade name BAREX™ from Innovene LLC of Chicago, Ill. Some other polymer materials, such as polyethylene naphthalate (PEN), polytrimethylene naphthalate (PTN), or some polyester-based liquid crystal polymers (LCP), may alternatively be employed to provide barrier characteristics that inhibit the migration of the tobacco constituents. Furthermore, glass wool, cellulose fibers, a tobacco matrix such as reconstituted sheet or tobacco leaf, shreds and the like or any other type inert material may be used to form the porous matrix <b>120</b>.

The porous matrix <b>120</b> may comprise a plurality of pores <b>122</b> that are arranged to permit the passage of air from a first portion <b>124</b> to a second portion <b>126</b>. In some embodiments, the pores <b>122</b> may be randomly oriented to form a network of miniature passages through which air may pass over the tobacco <b>130</b> disposed in the porous matrix <b>120</b>. In other embodiments, the pores <b>122</b> may be manufactured to have a generally predetermined pore orientation, such as a plurality of pores that extend in a generally axial direction within the porous matrix <b>120</b>. The porous matrix <b>120</b> may be formed in a manner to control the average pore size, pore volume, or both. For example, as described in more detail below, the porous matrix <b>120</b> may be formed using a plastic sintering process in which granules of a polymer material are subjected to a controlled heating process for a regulated period of time. Furthermore, the article <b>100</b> may be colored or wrapped in paper or reconstituted tobacco sheet after formation thereof as desired.

It should be understood that, in some embodiments, the tobacco article <b>100</b> may comprise one or more polymer materials other than the previously described BAREX™ material. For example, the porous matrix <b>120</b> or other portions of the article <b>100</b> may include one or more of the following polymer materials: acetals, acrylics such as polymethylmethacrylate and polyacrylonitrile, alkyds, polymer alloys, allyls such as diallyl phthalate and diallyl isophthalate, amines such as urea, formaldehyde, and melamine formaldehyde, cellulosics such as cellulose acetate, cellulaose triacetate, cellulose nitrate, ethyl cellulose, cellulose acetate propionate, cellulose acetate butyrate, hydroxypropyl cellulose, cellophane and rayon, chlorinated polyether, coumarone-indene, epoxy, fluorocarbons such as PTFE, FEP, PFA, PCTFE, ECTFE, ETFE, PVDF, and PVF, furan, hydrocarbon resins, nitrile resins, polyaryl ether, polyaryl sulfone, phenol-aralkyl, phenolic, polyamide (nylon), poly (amide-imide), polyaryl ether, polycarbonate, polyesters such as aromatic polyesters, thermoplastic polyester, PBT, PTMT, PET and unsaturated polyesters such as SMC and BMC, polyimides such as thermoplastic polyimide and thermoset polyimide, polymethyl pentene, polyolefins such as LDPE, LLDPE, HDPE, and UHMWPE, polypropylene, inomers such as PD and poly allomers, polyphenylene oxide, polyphenylene sulfide, polyurethanes, poly p-xylylene, silicones such as silicone fluids and elastomers, rigid silicones, styrenes such as PS, ADS, SAN, styrene butadiene latricies, and styrene based polymers, suflones such as polysulfone, polyether sulfone and polyphenyl sulfones, thermoplastic elastomers, and vinyls such as PVC, polyvinyl acetate, polyvinylidene chloride, polyvinyl alcohol, polyvinyl butyrate, polyvinyl formal, propylene-vinyl chloride copolymer, ethylvinyl acetate, and polyvinyl carbazole.

Still referring to <figref idref="DRAWINGS">FIG. 1</figref>, the tobacco <b>130</b> may be whole, shredded, cut, cured, aged, fermented, granulated or powdered, encapsulated, or otherwise processed. For example, as shown in <figref idref="DRAWINGS">FIG. 1</figref>, the tobacco <b>130</b> may be in a granulated or powdered form so that the tobacco <b>130</b> is sized to fit within the pores <b>122</b> of the porous matrix <b>120</b>. Further, it should be understood that the tobacco <b>130</b> may include an extract of tobacco that provides tobacco constituents (e.g., flavors, aromas, alkaloids, or the like), as described in more detail below. In some circumstances, some or all of the tobacco <b>130</b> in the article <b>100</b> may be processed from reconstituted tobacco.

In some embodiments, the tobacco <b>130</b> may include portions of leaves, flowers, roots, stems, or extracts thereof of any member of the genus <i>Nicotiana</i>. Exemplary species include <i>N. rustica </i>and <i>N. tabacum </i>(e.g., varieties and/or cultivars designated LA B21, LN KY171, TI 1406, Basma, Galpao, Perique, Beinhart 1000-1, and Petico). Other species include <i>N. acaulis, N. acuminata, N. acuminata </i>var. <i>multiflora, N. africana, N. alata, N. amplexicaulis, N. arentsii, N. attenuata, N. benavidesii, N. benthamiana, N. bigelovii, N. bonariensis, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. debneyi, N. excelsior, N. forgetiana, N. fragrans, N. glauca, N. glutinosa, N. goodspeedii, N. gossei, N. hybrid, N. ingulba, N. kawakamii, N. knightiana, N. langsdorffii, N. linearis, N. longiflora, N. maritima, N. megalosiphon, N. miersii, N. noctiflora, N. nudicaulis, N. obtusifolia, N. occidentalis, N. occidentalis subsp. hesperis, N. otophora, N. paniculata, N. pauciflora, N. petunioides, N. plumbaginifolia, N. quadrivalvis, N. raimondii, N. repanda, N. rosulata, N. rosulata </i>subsp. <i>ingulba, N. rotundifolia, N. setchellii, N. simulans, N. solanifolia, N. spegazzinii, N. stocktonii, N. suaveolens, N. sylvestris, N. thyrsiflora, N. tomentosa, N. tomentosiformis, N. trigonophylla, N. umbratica, N. undulata, N. velutina, N. wigandioides</i>, and <i>N. x sanderae. </i>

In some embodiments described herein, the tobacco <b>130</b> may include one or more components such as flavor extracts, flavor masking agents, bitterness receptor site blockers, receptor site enhancers, sweeteners, and additives such as chlorophyll, minerals, botanicals, or breath freshening agents. Some of these components are described, for example, in U.S. patent application Ser. Nos. 10/982,248 and 10/979,266, both of which are incorporated herein by reference. Such components may be present in the tobacco <b>130</b> as a powder, an oil, a powder in fine particulate form, or in encapsulated form.

In some embodiments, the tobacco <b>130</b> may be processed to include these flavor components prior to construction of the article <b>100</b>. For example, some components can be added by spraying a flavor extract. In another example, flavor can be imparted to tobacco <b>130</b> by combining solid or liquid flavor agents with a tobacco material and incubating under suitable conditions, as described, for example, in previously incorporated application Ser. No. 10/982,248. In addition, the tobacco <b>130</b> may be processed to include these flavor components after construction of the article <b>100</b> via capillary action, injection, or other introduction means.

Suitable flavors and flavor extracts include menthol, cinnamon, wintergreen, cherry, berry, peach, apple, spearmint, peppermint, bergamot, vanilla, coffee, a mint oil from species of the genus Mentha or other desired flavors. Flavors may also be provided by plant matter, e.g., mint leaves, which are typically 10% flavor oils and 90% insoluble fiber. Suitable plant matter may be obtained from plants such as clove, cinnamon, herb, cherry, peach, apple, lavender, rose, vanilla, lemon, orange, coffee, or species of the genus Mentha. Flavor may be provided by synthesized flavors, flavor extracts, plant matter, or a combination thereof. As further provided herein, flavor may also be provided by imitation, synthetic, or artificial flavor ingredients and blends containing such ingredients. Suitable sweeteners include sucralose, acesulfame potassium (Ace-K), aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, and mannitol.

Referring now to <figref idref="DRAWINGS">FIG. 2</figref>, some embodiments of the tobacco article <b>100</b> may be configured to expose the first and second portions <b>124</b> and <b>126</b> of the porous matrix <b>120</b>. For example, in the embodiments in which the outer shell surface <b>110</b> includes first and second cap surfaces <b>114</b> and <b>116</b>, at least a portion of each cap surface <b>114</b> or <b>116</b> may be cut, punctured, or otherwise removed to expose the first and second ends <b>124</b> and <b>126</b> of the porous matrix <b>120</b>. This removal process may be performed during the manufacturing or packaging of the tobacco article <b>100</b> (e.g., cutting the cap surfaces <b>114</b> and <b>116</b> to provide a uniform length of the article and then wrapping one or more articles <b>100</b> in an impermeable package) or may be performed by the consumer immediately before using the tobacco article <b>100</b>. In some embodiments, the tobacco article <b>100</b> may be supplied to the consumer in a package that includes a cutter mechanism or a puncture mechanism to facilitate the use of the tobacco article. When the cap surfaces <b>114</b> and <b>116</b> are removed, the longitudinally extending surface <b>112</b> of the outer shell surface <b>110</b> may remain intact so as to substantially surround the outer radial area of the porous matrix <b>120</b>. The first and second portions <b>124</b> and <b>126</b> of the porous matrix <b>120</b> may be exposed to the atmosphere so that air may be passed through the network of pores <b>122</b> and over the tobacco <b>130</b> disposed therein. As further provided herein, some embodiments of the tobacco article <b>100</b> may be configured to expose the first and second portions <b>124</b> and <b>126</b> of the porous matrix <b>120</b> during manufacturing thus eliminating the need to cut the cap surfaces <b>114</b> and <b>116</b>.

Referring to <figref idref="DRAWINGS">FIG. 3</figref>, some embodiments of the tobacco article <b>100</b> may be adapted to provide tobacco or tobacco constituents to a consumer in the form of a liquid, vapor or, in particular circumstances, a combination of vapor and fine particles or a combination of vapor and fine particles. In this embodiment, the first and second portions <b>124</b> and <b>126</b> of the porous matrix <b>120</b> may be exposed to the atmosphere, and a consumer may force air from the first portion <b>124</b>, through the network of pores <b>122</b> and over the tobacco <b>130</b> disposed therein, and out from the second portion <b>126</b>. For example, the consumer may create a negative pressure on the tobacco article <b>100</b> proximal to the second portion <b>126</b> so that the air is drawn through the porous matrix <b>120</b> and into the consumer. As the air passes through the porous matrix <b>120</b>, tobacco constituents <b>132</b> may be introduced into the air and are provided to the consumer. The tobacco constituents (e.g., flavors, aromas, alkaloids, or the like) may be in the form of vapor that transfers from the tobacco <b>130</b> to the air that is passed through the porous matrix <b>120</b>. As previously described, the tobacco <b>130</b> may be supplemented with extract of tobacco that provides additional tobacco constituents to the tobacco <b>130</b> in the porous matrix <b>120</b>, thereby further increasing the level of tobacco constituents <b>132</b> that may be experienced by the consumer. Accordingly, the tobacco article <b>100</b> may provide tobacco satisfaction in the form of the experience associated with tobacco organoleptic components and added flavor components that are released upon usage. Such organoleptic components may relate or contribute to the integrated sensory perception by the consumer that includes, for example, any combination of aroma, fragrance, flavor, taste, odor, mouth feel, or the like. Further, the tobacco article <b>100</b> may provide the tobacco constituents <b>132</b> to the consumer without combusting the tobacco article <b>100</b> or the tobacco <b>130</b> disposed therein. As previously described, tobacco <b>130</b> may include one or more flavor agents, or flavor agent particles may be disposed in the pores <b>122</b> of the porous matrix <b>120</b>. In these circumstances, the flavor agents may be introduced into the air so that a combination of flavor agents and tobacco constituents <b>132</b> are provided to the consumer.

In particular embodiments, the tobacco <b>130</b> may be arranged in a manner that permits the tobacco article <b>100</b> to provide tobacco and tobacco constituents to a consumer in the form of vapor and fine particles. For example, the tobacco <b>130</b> in the porous matrix <b>120</b> may be finely granulated so that fine tobacco particles are capable of passing through the network of pores <b>122</b> in the porous matrix <b>120</b>. In such circumstances, the consumer may suck on the tobacco article <b>100</b> proximal to the second portion <b>126</b> so that the air is drawn through the porous matrix <b>120</b> by the consumer. As the air passes through the porous matrix <b>120</b>, the fine tobacco particles and tobacco constituents <b>132</b> may be provided to the consumer as a combination of vapor and fine particles. Again, the tobacco article <b>100</b> may provide tobacco satisfaction to the consumer without combusting the tobacco article <b>100</b> or the tobacco <b>130</b> disposed therein.

<figref idref="DRAWINGS">FIGS. 4A-B</figref> describe an example of a plastic sintering process to form the porous matrix <b>120</b> or the entire article <b>100</b>. Such a plastic sintering process may include controlled application of heat using one of a variety of heating techniques, some of which are described, for example, in U.S. Pat. No. 4,375,441 to Adams et al. (which is incorporated herein by reference). It should be understood that plastic sintering is only one process of several possible processes that may be used to form the porous matrix of the tobacco articles described herein.

Referring now to <figref idref="DRAWINGS">FIGS. 4A-B</figref>, some embodiments of the tobacco article <b>100</b> may be integrally formed in a molding process. In this embodiment, the outer shell surface <b>110</b> and the porous matrix <b>120</b> may be integrally formed using a plastic sintering process. In some circumstances, the tobacco <b>130</b> may be mixed with the polymer granules <b>128</b> during the molding process so that the tobacco <b>130</b> is integrally molded with the porous matrix <b>120</b>. It should be understood that, in other embodiments, the tobacco <b>130</b> may be integrally molded with the porous matrix <b>120</b> without necessarily forming the outer shell surface <b>110</b>. Also, it should be understood that the tobacco <b>130</b> can be pressure injected into the porous matrix <b>120</b> after the formation of the porous matrix <b>120</b> (e.g., the tobacco <b>130</b> may not be integrally molded with the porous matrix <b>120</b>).

As shown in <figref idref="DRAWINGS">FIG. 4A</figref>, the formation process may include first and second mold pieces <b>170</b> and <b>180</b> that may fit together to define and internal cavity <b>175</b>. The internal cavity <b>175</b> may include machined surfaces that at least partially define the desired outer shape of the tobacco article <b>100</b>. The tobacco <b>130</b> and the polymer resins that are combined to form the tobacco article <b>100</b> may be placed in the internal cavity <b>175</b>. As previously described, the outer shell surface <b>110</b> may be formed to have a generally continuous layer of material that is impermeable to the migration of tobacco constituents, such as BAREX™ material. Accordingly, granules <b>118</b> of this copolymer may be arranged along the outer portions of the internal cavity <b>175</b> so that these granules <b>118</b> can be merged to form at least a portion of the outer shell surface <b>110</b> during the plastic sintering process. The granules <b>128</b> of polymer material that form at least a portion of the porous matrix <b>120</b> may be arranged in a central portion of the internal cavity <b>175</b>. As described in more detail below, these granules <b>128</b> may comprise a different polymer material and may have a larger average size that the outer granules <b>118</b> so as to provide a network of pores <b>122</b> after the molding process. Further, the tobacco <b>130</b> may be mixed with the central granules <b>128</b> before or during insertion into the cavity <b>175</b>. Accordingly, the tobacco <b>130</b> may be intermixed with the granules <b>128</b> during the plastic sintering process so that at least a portion of the tobacco <b>130</b> is disposed in the pores <b>122</b> after the granules <b>128</b> have formed the porous matrix <b>120</b>. (It should be understood that the granules <b>118</b> and <b>128</b> and the tobacco <b>130</b> are not necessarily drawn to scale, and the sizes may be exaggerated for purposes of illustration.)

Referring to <figref idref="DRAWINGS">FIG. 4B</figref>, when the granules <b>118</b> and <b>128</b> and the tobacco <b>130</b> are arranged in the mold cavity <b>175</b>, the mold pieces <b>170</b> and <b>180</b> may apply pressure while the granules <b>118</b> and <b>128</b> are heated in for a controlled period of time. Such pressure and heat causes the outer shell surface <b>110</b> to form into its desired shape while the central granules <b>128</b> are controllably melted for a limited period of time. While it is not intended that the present invention be limited by any theory by which it achieves its advantageous result, it is believed that, during this plastic sintering process, the outer granules <b>118</b> may melt at a faster rate to form a substantially continuous layer along the outer shells surface <b>110</b>, while the central granules <b>128</b> melt at a slower rate (e.g., the granule surfaces may partially heat to bond with adjacent granules even though some of the granules <b>128</b> may not completely melt). Such a process may form a porous matrix <b>120</b> that is at least partially surrounded by the outer shell surface <b>110</b>. It should be understood that some portion of the central granules <b>128</b> may melt and merge with outer granules along a transition zone near the outer shell surface <b>110</b>. In some circumstances, the central granules <b>128</b> may comprise a different polymer material, may have a larger average size, or both compared to the outer granules <b>118</b> so as facilitate the slower melting rate of the granules <b>128</b> along the interior of the tobacco article <b>100</b>. Because the tobacco <b>130</b> was mixed with the central granules <b>128</b>, at least a portion of the tobacco <b>130</b> may be disposed in the pores <b>122</b> after the granules <b>128</b> have formed the porous matrix <b>120</b>. It should be understood that some characteristics of the pores <b>122</b> (e.g., average pore size, average pore volume, or the like) may be selected by varying, for example, the size of granule materials used to form the porous matrix <b>120</b>, the temperature level at which the granules <b>128</b> are heated, the amount of time at which the granules <b>128</b> are heated, and the pressure used in a molding process.

In this embodiment, the central granules <b>128</b> comprise the same copolymer material (e.g., BAREX™) as the outer granules <b>118</b>, and the central granules may have a larger average size than the outer granules. It should be understood that, in some circumstances, the central granules <b>128</b> and the outer granules <b>118</b> may have similar average sizes. In some embodiments, the central granules <b>128</b> may comprise a material other than the outer granules <b>118</b> so that the porous matrix <b>120</b> generally comprises a different material that the outer shell surface <b>110</b>. For example, the central granules may comprise a plastic polymer material, such as polyethylene or polypropylene. Further, the porous matrix <b>120</b> may generally comprise a polymer material that is water soluble or water insoluble. It should be understood that a variety of material specifications (e.g., granule size and molecular weight, granule size distribution, material type, tobacco particle size, tobacco particle distribution, and the ratio of polymer granules to tobacco particle) and also a variety of process parameters (e.g., temperature, heat exposure time, and pressure) may be used in accordance with the invention to provide a porous matrix <b>120</b> having advantageous characteristics.

Referring now to <figref idref="DRAWINGS">FIGS. 5A-B</figref>, the tobacco <b>130</b> that is disposed in the tobacco article <b>100</b> may include extracts of tobacco that provide additional tobacco constituents (e.g., flavors, aromas, alkaloids, or the like). As previously described, these additional tobacco constituents may increase the amount of tobacco constituents that are experienced by the consumer during ordinary use of the tobacco article <b>100</b>. As shown in <figref idref="DRAWINGS">FIG. 5A</figref>, a plurality of tobacco leaves <b>190</b> (or flowers or roots or stems) may be subjected to an extraction process that provides a solid or liquid extract <b>192</b> having tobacco constituents therein. For example, an aqueous extraction process may be used. As shown in <figref idref="DRAWINGS">FIG. 5B</figref>, the tobacco liquid extract <b>192</b> may be applied to tobacco <b>194</b> that is whole, shredded, cut, cured, aged, granulated or powdered, or otherwise processed. In some embodiments, a portion of the extracted tobacco <b>190</b> (<figref idref="DRAWINGS">FIG. 5A</figref>) may be discarded and the tobacco liquid extract <b>192</b> may be applied a lesser amount of the tobacco <b>194</b> (<figref idref="DRAWINGS">FIG. 5B</figref>). As such, the tobacco <b>194</b> (<figref idref="DRAWINGS">FIG. 5B</figref>) may include tobacco constituents in an amount equal to or greater than that which was originally extracted. These additional tobacco constituents may increase the amount of constituents that are experienced by the consumer during ordinary use of the tobacco article <b>100</b>. While it is not intended that the present invention be limited by any theory by which it achieves its result, it is believed that, a substantial portion of the tobacco extract <b>192</b> may remain on the outer surface of the tobacco <b>194</b>, thereby facilitating the transfer of the tobacco constituents from the tobacco in the article <b>100</b> to the air or liquid that is passed through the porous matrix <b>120</b>. Tobacco constituents can include carotenoids such as beta-damascenone and megastigmatrienones, alkaloids such as nicotine, and terpenoids such as limonene. The tobacco that includes the tobacco extract <b>192</b> may be granulated or powdered to facilitate the placement of the tobacco within the porous matrix <b>120</b>. As shown in <figref idref="DRAWINGS">FIG. 6</figref>, the granulated or powdered tobacco <b>130</b> may be mixed with granules <b>128</b> of polymer material at a selected ratio, and the mixture may then be used in an integral molding process (as described, for example, in connection with <figref idref="DRAWINGS">FIGS. 4A-B</figref>).

Referring now to <figref idref="DRAWINGS">FIG. 7</figref>, some embodiments of a tobacco article <b>200</b> may include porous matrix <b>220</b> that is formed separately from an outer shell <b>210</b>. The porous matrix <b>220</b> may be formed using a plastic sintering process (as described in connection with <figref idref="DRAWINGS">FIGS. 4A-B</figref>). Alternatively, the porous matrix <b>220</b> may be formed using a different process in which the porous matrix <b>220</b> comprises a porous glass or ceramic material having tobacco disposed in the pores <b>222</b> or in which the porous matrix <b>220</b> comprises a fibrous material having a network of pores to receive the tobacco <b>130</b> therein. Depending on the formation process of the porous matrix <b>220</b>, the tobacco <b>130</b> may be integrally molded with the porous matrix <b>220</b> or may be pressure injected into the porous matrix <b>220</b> so that the tobacco <b>130</b> is disposed in the pores <b>222</b>. The porous matrix <b>220</b> may be formed or otherwise configured to mate with a separate shell <b>210</b>. In this embodiment, the separate shell <b>210</b> comprises a tubular configuration having an open end <b>216</b> to receive the porous matrix <b>220</b>. As such, the porous matrix <b>220</b> may be slid into and engage the separate shell <b>210</b>.

As previously described, the outer shell <b>210</b> may comprise a continuous layer of material that is impermeable to migration of the tobacco and tobacco constituents, such as BAREX™ material. In those embodiments in which the porous matrix <b>220</b> should be sealed until being used by a consumer, the separate shell <b>210</b> may comprise a tube of BAREX™ that is sealed at the open ends thereof after the porous matrix <b>220</b> is inserted into the shell <b>210</b>. For example, the open ends of the tubular shell <b>210</b> may be heat sealed using BAREX™ cap walls. In another example, the open ends of the tubular shell <b>210</b> may be heat sealed using a heat pinching process.

Referring to <figref idref="DRAWINGS">FIG. 8</figref>, some embodiments of a tobacco article <b>300</b> may include a porous matrix <b>320</b> that is formed separately from an outer shell <b>310</b> and from the tobacco <b>130</b>. For example, a first porous matrix <b>320</b> and a second porous matrix <b>325</b> may be formed using a plastic sintering process (as described in connection with <figref idref="DRAWINGS">FIGS. 4A-B</figref>) or using an alternative forming process. The tobacco <b>130</b> may be whole, shredded, cut, cured, aged, granulated or powdered, or otherwise processed, and may be disposed in the outer shell <b>310</b> between the first porous matrix <b>320</b> and the second porous matrix <b>325</b>. The first porous matrix <b>320</b> and the second porous matrix <b>325</b> may comprise networks of pores <b>322</b> through which air and tobacco constituents may pass, yet the pores may be sized to permit the passage of only fine tobacco particles. The first porous matrix <b>320</b> and the second porous matrix <b>325</b> may be formed or otherwise configured to mate with the separate shell <b>310</b>. In this embodiment, the separate shell <b>310</b> comprises a tubular configuration having an open end <b>316</b> to receive the first porous matrix <b>320</b>, the tobacco <b>130</b>, and the second porous matrix <b>325</b>. As previously described, the separate shell <b>310</b> may comprise a tube of BAREX™ that is sealed at the open ends thereof after the first porous matrix <b>320</b>, the tobacco <b>130</b>, and the second porous matrix <b>330</b> are inserted into the shell <b>310</b>. For example, the open ends of the tubular shell <b>310</b> may be heat sealed using BAREX™ cap walls. In another example, the open ends of the tubular shell <b>310</b> may be heat sealed using a heat pinching process.

Optionally, at least one of the first porous matrix <b>320</b> and the second porous matrix <b>330</b> may include a frusto-conical channel formed therein to provide a jet stream of air toward the tobacco <b>130</b> disposed in the tobacco article <b>300</b>. In such embodiments, air may be forced into the opening of the frusto-conical channel by the consumer drawing air from the opposite end of the tobacco article <b>300</b>. The flow of air through the channel <b>329</b> may increase the air velocity that passes over the tobacco <b>130</b>, thereby facilitating the transfer of tobacco particles, tobacco constituents, or both tobacco particles and tobacco constituents from the tobacco <b>130</b> to the air. It should be understood that such a frusto-conical channel may be formed in the porous matrix of other tobacco articles, such as those described in connection with <figref idref="DRAWINGS">FIGS. 1-3 and 7</figref>.

Referring now to <figref idref="DRAWINGS">FIGS. 9-11</figref>, some embodiments of a tobacco article <b>400</b> may be adapted to provide tobacco and/or tobacco constituents to a consumer in the form of a liquid. Such embodiments of the tobacco article <b>400</b> may include tobacco <b>130</b> disposed in a porous matrix <b>420</b>, as described, for example, in connection with <figref idref="DRAWINGS">FIGS. 1-7</figref>. The porous matrix <b>420</b> may be form using a plastic sintering process (as described in connection with <figref idref="DRAWINGS">FIGS. 4A-B</figref>). Alternatively, the porous matrix <b>420</b> may be formed using a different process in which the porous matrix <b>420</b> comprises a porous glass or ceramic material having tobacco disposed in the pores <b>422</b> or in which the porous matrix <b>420</b> comprises a fibrous material having a network of pores to receive the tobacco <b>130</b> therein. Depending on the formation process of the porous matrix <b>420</b>, the tobacco <b>130</b> may be integrally molded with the porous matrix <b>420</b> or may be pressure injected into the porous matrix <b>420</b> so that the tobacco <b>130</b> is disposed in the pores <b>422</b>. Also, the tobacco article <b>400</b> may include a conduit <b>410</b> that surrounds at least a portion of the porous matrix <b>420</b>. The conduit <b>410</b> may be integrally formed with the porous matrix <b>420</b> (as described, for example, in connection with <figref idref="DRAWINGS">FIGS. 4A-B</figref>), or the conduit <b>410</b> may be formed separately from the porous matrix <b>420</b> (as described, for example, in connection with <figref idref="DRAWINGS">FIGS. 7 and 8</figref>). In this embodiment, the conduit <b>410</b> is illustrated having a cylindrical shape, but the conduit <b>410</b> may have a different shape. The conduit <b>410</b> may comprise a material that prevents the migration of liquid from the outer radial area of the porous matrix <b>420</b>. As such, any liquid disposed in the porous matrix <b>420</b> is forced to pass through an exposed portion <b>424</b> or <b>426</b> of the porous matrix <b>420</b>.

As shown in <figref idref="DRAWINGS">FIG. 10</figref>, at least a portion of the porous matrix <b>420</b> may be temporarily exposed to a liquid <b>440</b> so that the liquid <b>440</b> is introduced into the pores <b>422</b>. For example, the liquid <b>440</b> may progress into the pores <b>422</b> of the porous matrix <b>420</b> through capillary action <b>445</b> so that some portion of the liquid remains in the porous matrix <b>420</b> even after the tobacco article <b>400</b> is removed from the liquid container <b>442</b>. In some embodiments, the liquid <b>440</b> can include water.

As shown in <figref idref="DRAWINGS">FIG. 11</figref>, the first and second portions <b>424</b> and <b>426</b> of the porous matrix <b>420</b> may be exposed to the atmosphere, and a consumer may force air from the first portion <b>424</b> and into the network of pores <b>422</b>. The consumer's vacuum action may cause the liquid <b>440</b> that was previously introduced into the first portion <b>424</b> of the porous matrix <b>420</b> to pass over the tobacco <b>130</b> disposed in the pores. As such, the liquid <b>440</b> is drawn through the porous matrix <b>420</b> and to the consumer. As the liquid <b>440</b> passes through the porous matrix <b>420</b>, tobacco and/or tobacco constituents <b>132</b> may be introduced into the liquid <b>440</b> so that the tobacco and/or tobacco constituents are experienced by the consumer. The tobacco and/or tobacco constituents <b>132</b> may be mixed with the liquid <b>440</b>.

As previously described, the tobacco <b>130</b> may include extract of tobacco that provides additional tobacco constituents to the tobacco <b>130</b> in the porous matrix <b>420</b>, thereby further increasing the level of tobacco constituents <b>132</b> that may be introduced in the liquid <b>440</b> for providing to the consumer. Accordingly, the tobacco article <b>100</b> may provide tobacco satisfaction to the consumer without combusting the tobacco article <b>400</b> or the tobacco <b>130</b> disposed therein. Optionally, the tobacco <b>130</b> may include one or more flavor agents or other components (as previously described), or flavor agent particles may be disposed in the pores <b>422</b> of the porous matrix <b>420</b>. In such circumstances, the flavor agents may be introduced into the liquid <b>440</b> so that a combination of flavor agents, tobacco and tobacco constituents <b>132</b> are experienced by the consumer.

Referring now to <figref idref="DRAWINGS">FIGS. 12-14</figref>, some embodiments of a tobacco article <b>500</b> may be adapted to be wholly received by the consumer and to introduce tobacco and/or tobacco constituents into the consumer's saliva. The tobacco article <b>500</b> may be configured to resemble a tobacco pouch. In this embodiment, the tobacco article <b>500</b> has generally elliptical shape, but other embodiments may have a pillow shape, a circular shape, a flat rectangular shape, or the like. Such embodiments of the tobacco article <b>500</b> may include tobacco <b>130</b> disposed in a first porous matrix <b>520</b>, as described, for example, in connection with <figref idref="DRAWINGS">FIGS. 1-7</figref>. The first porous matrix <b>520</b> may be formed using a plastic sintering process (as described in connection with <figref idref="DRAWINGS">FIGS. 4A-B</figref>) or using an alternate process. Depending on the formation process of the porous matrix <b>520</b>, the tobacco <b>130</b> may be integrally molded with the porous matrix <b>520</b> or may be pressure injected into the porous matrix <b>520</b> so that the tobacco <b>130</b> is disposed in the pores <b>522</b>.

Optionally, the tobacco article <b>500</b> may include a second porous matrix <b>550</b> that, in some circumstances, can serve as a saliva reservoir. The saliva reservoir <b>550</b> may be a porous matrix that is integrally formed with the first porous matrix <b>520</b> that contains the tobacco <b>130</b>. The saliva reservoir <b>550</b> may include pores <b>552</b> having a substantially greater pore size and pore volume than the first porous matrix <b>520</b>. For example, the saliva reservoir <b>550</b> may be formed from polymer granules having a much larger size than the granules used to form the first porous matrix <b>520</b>. Thus, during a plastic sintering process, the saliva reservoir <b>550</b> may become a porous matrix having pores <b>552</b> that are greater in size than the pores <b>522</b> of the first porous matrix <b>520</b>.

As shown in <figref idref="DRAWINGS">FIG. 13</figref>, the tobacco article <b>500</b> may be wholly received by the consumer. For example, the tobacco article <b>500</b> may be placed between the gums and the lip of the consumer. In such circumstances, the tobacco article <b>500</b> may be exposed to the consumer's saliva.

Referring to <figref idref="DRAWINGS">FIG. 14</figref>, when the first porous matrix <b>520</b> is be exposed to the consumer's saliva <b>540</b>, a portion of the consumer's saliva <b>540</b> will be forced into the pores <b>522</b>. The saliva <b>540</b> may pass through the network of pores <b>522</b> so that tobacco constituents <b>132</b> (and, in some cases, fine tobacco particles) are introduced into the consumer's saliva. Accordingly, the tobacco constituents <b>132</b> may mix with the saliva <b>440</b> and subsequently be ingested by the consumer. While the tobacco, tobacco constituents, or both tobacco and tobacco constituents are provided to the consumer, the saliva reservoir <b>550</b> may absorb some portion of the saliva of the consumer, which may reduce the amount of spitting normally associated with chewing tobacco or snuff. As previously described, the tobacco <b>130</b> may be supplemented with extract of tobacco that provides additional tobacco constituents to the tobacco <b>130</b> in the first porous matrix <b>520</b>, thereby increasing the level of tobacco constituents <b>132</b> that may be introduced in the saliva <b>540</b> for providing to the consumer. Accordingly, the tobacco article <b>100</b> may provide tobacco satisfaction to the consumer without combusting the tobacco article <b>500</b> or the tobacco <b>130</b> disposed therein. Optionally, the tobacco <b>130</b> may include one or more flavor agents or other components (as previously described), or flavor agent particles may be disposed in the pores <b>522</b> of the porous matrix <b>520</b>. In such circumstances, the flavor agents may be introduced into the liquid saliva so that a combination of flavor agents and tobacco constituents <b>132</b> are provided to the consumer.

When the tobacco <b>130</b> in the porous reservoir <b>520</b> is exhausted or the consumer decides to remove the tobacco article <b>500</b>, the tobacco article may be discarded. Thus, the tobacco article <b>500</b> may be discretely discarded with some portion of the consumer's saliva retained in the saliva reservoir <b>550</b>.

A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope